KTM 85 SX 2011 Owner's Manual
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KTM 85 SX 2011 Owner's Manual

KTM 85 SX 2011 Owner's Manual

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OWNER'S MANUAL
2011
85 SX
105 SX
3211595 en

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Summary of Contents for KTM 85 SX 2011

  • Page 1 OWNER’S MANUAL 2011 85 SX 105 SX 3211595 en...
  • Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
  • Page 3 » IMPORTANT INFORMATION INTENDED PURPOSE KTM mini-sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations.
  • Page 4 SPARE PARTS, ACCESSORIES For the safety of your child, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.

  • Page 5: Important Information For Parents About Safe Driving

    » IMPORTANT INFORMATION FOR PARENTS ABOUT SAFE DRIVING The 85/105 SX mini motorcycles are off-road motorcycles designed for one person only. They are not allowed on public roads. The vehicle dimensions and components are designed for children from 10 to 15 years of age with a maximum weight of 75 kg (33,98 lb).

  • Page 6: Table Of Contents

    Clutch lever .......6 General information about KTM disc brakes ..21 Hand brake lever .

  • Page 7: Serial Number Locations

    » SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the carburetor.

  • Page 8: Short Circuit Button

    » OPERATION INSTRUMENTS Short circuit button The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without kinks.

  • Page 9: Kickstarter

    » OPERATION INSTRUMENTS Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work).

  • Page 10: Damping Action During Compression Of Shock Absorber

    » OPERATION INSTRUMENTS Damping action during compression of shock absorber The shock absorber on the models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle.

  • Page 11: General Tips And Warnings For Starting The Motorcycle

    – Make sure the work for the "pre-delivery inspection" was per- – Have your youngster wear proper protective gear whenever formed by your authorized KTM workshop. The DELIVERY he or she rides the motorcycle: helmet, eye protection, chest, CERTIFICATE and SERVICE MANUAL will be handed over back, arm and leg protectors, gloves and boots.

  • Page 12: Driving Instructions

    » DRIVING INSTRUCTIONS Checks and maintenance measures when preparing for use NOTE: Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the gear oil level. –...

  • Page 13: Starting When The Engine Is Cold

    » DRIVING INSTRUCTIONS Starting when the engine is cold 1 Open fuel tap [1] . 2 Put the gear in neutral 3 Activate the cold-starting aid (choke) [2]. 4 Leave throttle closed and kick down the kickstarter vigorously all the way. –...

  • Page 14: Refueling, Fuel

    If gasoline is swallowed or splashed in the eyes, seek should stop immediately, turn the engine off, and contact a doctor’s advice immediately. an authorized KTM dealer. Braking – Only use premium-grade gasoline RON 98 mixed with high- Turn off the gas and apply the hand and foot brakes at the same grade two-stroke engine oil.

  • Page 15: Service Schedule

    » SERVICE SCHEDULE...
  • Page 16 All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 17: Maintenance Work On Chassis And Engine

    OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out.

  • Page 18: Cleaning The Dust Sleeves Of The Telescopic Fork

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [1] are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows.

  • Page 19: Basic Suspension Setup For The Weight Of The Driver

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your child's weight.

  • Page 20: Overview Of The Shock Absorber Springs

    Front fork 85/105 SX If your child weights less than 45 kg or more than 55 kg, have your KTM work- shop mount suitable fork springs. The illustration on the left shows the cor- rect spring rate. The standard spring is shown in bold print.

  • Page 21: Checking Chain Tension

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 22: General Information About Ktm Disc Brakes

    DOT 4 brake fluid. Do not, in any event, use DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTM motor- cycle gaskets and brake hoses are not designed for DOT 5 brake fluid.

  • Page 23: Checking The Brake Fluid Level/ Refilling

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the brake fluid level/ refilling * The brake fluid reservoir is combined with the hand brake cylinder on the handlebar. To check the brake fluid level, press the brake pistons back into the basic position.

  • Page 24: Changing Basic Position Of The Brake Pedal

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Changing basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller [1]. Using the push rod [2], the free play on the foot brake pedal must be set.

  • Page 25: Replacing The Rear Brake Pads

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 26: Dismounting And Mounting The Rear Wheel

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 27: Cleaning The Air Filter

    Mount the silencer and check the exhaust system for tightness. Note: Glass fiber yarn packages are offered by your licensed KTM dealer. The exhaust system becomes very hot while the motorcycle is running. To avoid burns do not start work on the exhaust system until it has properly cooled down.

  • Page 28: Changing The Original Position Of The Clutch Lever

    SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore [7] of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with...

  • Page 29: Cooling System

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system The water pump [1] in the engine keeps the cooling liquid in circulation. The cooling liquid is cooled by the air stream. Therefore, the cooling effect is reduced when the traveling speed is reduced. Dirty radiators additionally reduce the cooling effect.

  • Page 30: Carburetor Adjustment

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (RON 98). Mixing ratio 2-stroke motor oil : super fuel 1:40.

  • Page 31: Draining The Float Chamber Of The Carburetor

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber leads to engine malfunction. Make sure you do this while the engine is cold.

  • Page 32: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 33 » TROUBLE SHOOTING TROUBLE CAUSE REMEDY Engine has not enough power Reed paddles tensionless or Replace reed paddles or reed valve housing damaged, surface of reed valve housing damaged Wear Overhaul engine Engine revs not up and running Carburetor overflows if level Clean carburetor, if necessary replace float needle and adjust level in four stroke cycle adjust too high, float needle seat-...

  • Page 34: Cleaning

    » CLEANING Clean your motorcycle regularly in order to keep its painted finish looking shiny and new. The best manner would be to use warm water that has been mixed with a commercially available washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet.

  • Page 35: Technical Specifications - Chassis

    » TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 85 SX (17”/14”) 85 SX 105 SX (19”/16”) Frame Central chrome-moly-steel frame Fork telescopic fork WP Suspension 4357 MXMA Wheel travel front/rear 270 mm / 300 mm (10.62/11.81 in) Rear suspension WP PDS 4618 (Progressive Damping System) shock absorber Front brake Disc brake Ø...

  • Page 36: Technical Specifications - Engine

    » TECHNICAL SPECIFICATIONS - CHASSIS TIGHTENING TORQUES - CHASSIS Hexagon bolt - brake caliper front Loctite 243 + 25 Nm Hexagon head screw - brake pads rear 5 Nm Flat head bolt - brake discs 14 Nm Hexagon nut - front wheel spindle M10x1.5 40 Nm Hexagon nut - rear wheel spindle...
  • Page 37 » TECHNICAL SPECIFICATIONS - ENGINE ENGINE 85 SX 105 SX Design Liquid cooled single cylinder two-stroke engine with reed valve intake Displacement 84.93 ccm 103.96 ccm Bore/stroke 47 / 48.95 mm 52 / 48.95 mm Fuel unleaded fuel with at least RON 98 (USA = Premium RON 94), mixed with high grade two-stroke oil Oil/gasoline ratio 1 : 40 when using high grade two-stroke oil (e.g.

  • Page 38: Carburetor Setting

    » CARBURETOR SETTING VERGASERREGULIERUNG 85/105 SX 2011 CARBURETOR SETTING KEIHIN PWK 28 MEERESHÖHE TEMPERATUR - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C 16°C bis 24°C 25°C bis 38°C ALTITUDE TEMPERATURE -2°F to 20°F 19°F to 41°F 42°F to 60°F 61°F to 78°F 79°F to 98°F 1,75...

  • Page 39: Head Word Index

    Breather plug front fork ..... .16 General information about KTM disc brakes ..21 Carburetor adjustment .
  • Page 42 *3211595en* 3211595en KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com...

This manual is also suitable for:

105 sx 2011

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